Energy Absorption - Plascore
Engineered HoneycombSolutions and ServicesEnergy AbsorptionA guide to kinetic energymanagement systems
What’s in this Guide What is an Energy Absorber? Energy Absorption Terminology Types of Plascore Energy Absorbers Example: Drop Protection Example: DampingApplications2 Crash Test Dummy Calibration Impact Protection Large Mass Drop Protection Overrun Protection Nuclear Industry Compliance Aerospace Automotive Blast MitigationPlascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.1220
What is an Energy Absorber?Energy AbsorbedCrush DistanceForce“The basic conceptof energy absorptionis to take a movingobject’s kineticenergy and convert itinto internal work.”When a load is applied to the honeycomb itexhibits plastic deformation, in the form ofcrushing.This deformation results in a constant forcethrough the crushed thickness.The work (Force x Distance) done by theenergy absorber defines how much kineticenergy the system has absorbed.Bitzer T. (1997). Honeycomb Technology Materials, Design,Manufacture, Applications and Testing. Great Britain:Chapman & Hall.Before and after crushlite and AlTuCore assembly crushingPlascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.12203
Energy Absorption TerminologyBelow is a sample graph (using data from pre-crushed 320 PSI Crush Core) that explains the basicterminology of Plascore’s energy absorbers.320 PSI Crush Core (Pre-crushed)1.2.3.4Kinetic Energy Absorbed: Defined asthe work (force x distance) done.4.Crush Stroke: The length a part is crushed.5.Densification: Occurs when all material has beenfully crushed. Compressive stress will increaseexponentially from that point forward.6.Pre-crush: A procedure to eliminate peak barecompressive loading by initiating the crushingprocess on one side of the core.Crush Strength Tolerance: Theacceptable range the average crushstrength can be.Crush Strength: Defined in accordanceto ASTM D7336 as the averagecompressive stress during the core’sstable crush strength region.Plascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.1220
Types of Plascore Energy AbsorbersPlascore manufactures two different materials that are ideal for energy absorption applications. Thefirst of these is CrushLite, a lower density expanded aluminum honeycomb. The second is AlTuCore, ahigh-density corrugated material.CrushLite Typically manufactured in 4’ x 8’ sheets Customer specified thicknesses Crush strengths ranging from 7.5 – 750 psi Tested per ASTM D7336 Can be provided with or without pre-crush Typical thickness range: 1” – 30” Minimum stroke of 70% of part thickness.Standard* crush strength ranges:Density1.01.61.62.02.32.33.43.13.74.2Cell Size3/83/81/43/161/41/41/41/83/83/8Foil 0.00250.003Foil Alloy5052505250565052505250565052505650525052Crush Strength .76.05.76.18.18.1Cell Size1/41/81/83/83/161/43/161/81/81/8Foil 2FCFoil Alloy3003505250565052505250525056505650525052Crush Strength (psi)245275320350380420440535700750*Alternative crush strengths available on our Crush Lite data sheet. Minimum order quantity may apply.AlTuCore Cylindrical built to order energy absorber Customized ID and OD, based on customer’sneeds Test method similar to ASTM D7336 Can be provided with or without pre-crush Typical thickness range: 0.30” – 20” Custom crush strength ranges from 1,000 psito 8,000 psi Typical Stroke between 55% and 70% of partlength, depending on densityPlascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.12205
Example: Drop ProtectionThe Problem: An engineer has been tasked with arresting a large tensioning weight used on anindustrial conveyor belt. The tensioning weight poses a significant risk to equipment if it is allowed toplunge to the ground.KnownsUnknownsMaximum Load on Support Structure345,000 KnRequired Crush StrengthTBDpsi or MPaUsable Support Structure Width1 meterRequired MaterialTBDCrushLiteUsable Support Structure Length1.1 metersRequired Part ThicknessTBDin or mMaximum Drop Height3 metersMass of Tension Weight9,100Step 3:Step 1:Determine required part thickness:Determine required crush strength to maximizeload distribution.Governing equationPotential Energy (PE) Work (W)Maximum Crush Strength Maximum Load / CrushLiteAreaCrush Strength 0.38 MPa, or 56 psiStep 2:In this case:PE Mass x Gravity x (Drop Height Stroke)AndWork Crush Strength x Area x StrokeSelect a material.This results in the following equation:Referencing Plascore’s CrushLite data sheet:PACL - 1.6 - 1/4 - 0.0007 - 5056 with a Crush Strength of50 psi /-10% would be a perfect fit.Mass x Gravity x (Drop Height Stroke) CrushStrength x Area x StrokeSolving the above equation for stroke:Stroke 0.92 mUsing this information and Plascore’sadvertised minimum stroke of 70%:Part thickness Stroke / Minimum Percent StrokePart thickness 1.314 m of honeycombStep 4:Request a quote from Plascore.6Plascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.1220
Example: DampingThe Problem: An engineer is designing an amusement park ride and has the responsibly of ensuringthe safety of the occupants. In this case the engineer is designing for a catastrophic cart-to-cartimpact, and needs to ensure that the occupants are able to safely walk away. Based upon the usablearea, the AlTuCore OD and ID have been predefined.KnownsUnknownsMaximum Allowed “G” Load3 GsRequired StrokeCart Mass2,000 KgAlTuCore Outside Diameter0.1 metersAlTuCore Inside Diameter0.025 metersPart Length Required forSafe DecelerationRequired Part ThicknessWorst-Case Cart Velocity4 m/sCrush StrengthTBDinches or metersTBDinches or metersTBDinches or metersTBDpsiStep 2:Step 1:Determine the required part length to achievesafe deceleration. First, we have to determine therequired stroke.2“G” Load (Velocity) / (2 x Gravity x Stroke)Solving for strokeStroke 0.272 meters or 10.70 inchesNow we can use this information along withminimum available stroke of 55% to determinethe required part length.Part length Stroke/Expected Percent StrokePart length 0.494 meters or 19.458 inchesDetermine the required crush strength.Governing equationKinetic Energy Workin this case:Kinetic Energy ½ x Mass x Velocity2AndWork Crush Strength x Area x StrokeWe arrive at the equation:½ x Mass x Velocity2 Crush Strength x Area x StrokeSolving for crush strength:Crush Strength 8.0 MPa or 1159 psiStep 3:Request a quote for AlTuCorefrom Plascore.Plascore Energy Absorption Web: plascore.com Email: sales@plascore.com Phone: 616.772.12207
Corporate HeadquartersPlascore IncorporatedEuropePlascore GmbH & CoKG615 N. Fairview St.Zeeland, MI 49464-0170Feldborn 6D-55444 WaldlaubersheimGermanyPhone: 616.772.1220Toll-Free: 800.630.9257Fax: 616.772.1289plascore.comsales@plascore.comPhone: 49(0) 6707.9143 0Fax: 49(0) 6707.9143 40plascore.desales.europe@plascore.dePlascore, Inc. employs a quality management system that is AS/EN/JISQ 9100, ISO 9001:2008 and ISO 14001:2004 certified.IMPORTANT NOTICE: The information contained in these materials regarding Plascore’s products, processes, or equipment is intended to be up-to-date,accurate, and complete. However, Plascore cannot guarantee that this is always the case. Accordingly, it is a purchaser’s or user’s responsibility to performsufficient testing and evaluation to determine the suitability of Plascore’s products for a particular purpose. Information in these materials and productspecifications does not constitute an offer to sell. Your submission of an order to Plascore constitutes an offer to purchase which, if accepted by Plascore, shall besubject to Plascore’s terms and conditions of sale. PLASCORE MAKES TO WARRANTIES OF ANY KIND REGARDING THESE MATERIALS OR INFORMATION,EITHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE. Plascore owns and shall retain all worldwide rights in its intellectual property, and any other trademarks used in these materials are the property oftheir respective owners. The information in these materials shall not be construed as an inducement, permission, or recommendation to infringe any patent orother intellectual property rights of any third parties. 2021 Plascore, Inc. All Rights Reserved. v4.6.2021
Step 1: Determine required crush strength to maximize load distribution. Maximum Crush Strength Maximum Load / CrushLite Area Crush Strength 0.38 MPa, or 56 psi Step 2: Select a material. Referencing Plascore’s CrushLite data sheet: PACL - 1.6 - 1/4 - 0.0007 - 5056 with a Crush
ion coefficient. The average absorption coefficient is defined as the ratio between the total absorption in the hall to the total surface area of the hall. 2 Measurement of sound absorption coefficient. Let us consider a smaple fo. r which the absorption coefficient (a. m) is to be measured.
Trane Horizon Absorption Series Trane has led in absorption chiller design and manufacturing for four consecutive decades. In fact, Trane is the only North American chiller manufacturer to commercialize double-effect absorption, over 25 years ago. With over 10,000 absorption chillers manufactured and
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